Desktop Thermal Printers Service Manual

Transcription

1 Desktop Thermal Printers Service Manual Rev. B 2003 Zebra Technologies Corporation

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3 FOREWARD This manual provides spares replacement and service information for the 402, 2443, 2842, 2844, 3824, and 3844 series printers, manufactured by Zebra Technologies Corporation, Camarillo, California. TECHNICAL SUPPORT If for any reason you require product technical support, please contact the Distributor where you first purchased your equipment. If they cannot help you or at their direction, contact Zebra Repair Administration. RETURN MATERIALS AUTHORIZATION Before returning any equipment to Zebra for in warranty or out of warranty repair, contact Repair Administration for a Return Materials Authorization (RMA) number. Repack the equipment in the original packing material and mark the RMA number clearly on the outside. Ship the equipment, freight prepaid, to the address listed below: Zebra RMA, USA 1001 Flynn Road Camarillo, CA Phone: +1 (805) repair@zebra.com Label Printers: Card Printers: Zebra International, Europe Zebra International, Europe Zebra House, The Valley Centre Zone Indutrielle, Rue d'amsterdam Gordon Road, High Wycombe Varades, France Buckinghamshire HP13 6EQ, United Kingdom Phone: +33 (0) Phone: +44 (0) FAX: +33 (0) FAX: +44 (0) COPYRIGHT NOTICE This document contains information proprietary to Zebra Technologies Corporation. This document and the information contained within is copyrighted by Zebra Technologies Corporation and may not be duplicated in full or in part by any person without written approval from Zebra. While every effort has been made to keep the information contained within current and accurate as of the date of publication, no guarantee is given or implied that the document is error-free or that it is accurate with regard to any specification. Zebra reserves the right to make changes, for the purpose of product improvement, at any time Rev. B iii

4 TRADEMARKS The following desktop label and receipt bar code printers are service marks of Zebra Technologies Corporation. The printers are designated by: RESOLUTION THERMAL Two-Inch MAXIMUM PRINT WIDTH Four-Inch 200 dots per inch Direct Direct and Transfer (Ribbon) LP 2824 TLP 2824 LP 2844 LP 2844-Z LP 2443 Orion DA402 TLP 2844 TLP 2844-Z 300 dots per inch Direct and Transfer (Ribbon) TLP 3842 TLP 3844-Z Windows and MS-DOS are registered trademarks of Microsoft Corp. All other marks are trademarks or registered trademarks of their respective holders. iv Rev. B

5 OPERATOR CAUTIONS AND WARNINGS These pages de scribe gen eral safety and main te nance procedures that an operator must follow. They are ref er enced through out the service man ual. The man ual may in clude other warn ings and cau tions not dis played here. Warning - Shock Hazard The printer should never be op er ated in a lo ca tion where it can get wet. Per sonal in jury could re sult. Warning - Static Discharge Caution - Printer Setup & Handling Media Cautions & Tips The dis charge of elec tro static en ergy that ac cu mu lates on the sur face of the hu man body or other sur faces can dam age or de stroy the print head or elec tronic com po nents used in this de vice. TAKE ANTI-STATIC PRECAUTIONS before handling the print head or the elec tronic com po nents un der the print head as sem bly. 1)When installing or modifying the printer setup or configuration, ALWAYS TURN POWER OFF Before: A) Connecting any cables. B) Performing any cleaning or maintenance operations. C) Moving the printer. 2) Damage to the printer interface connector, accessories or enclosure may result from placing the printer on it s front bezel or backside during unpacking or handling. 1) Always use high quality approved labels and tags. Approved supplies can be ordered from your dealer. 2) If poor quality, adhesive backed labels are used, that DO NOT lay flat on the backing liner, the exposed edges may stick to the label guides and rollers inside the printer, causing the label to peel off from the liner and jam the printer. 3) DO NOT use non-approved transfer ribbon. Permanent damage to the print head may result if a non-approved ribbon is used. Non-approved ribbons maybe wound incorrectly for the printer or contain chemicals that may damage the print head. 4) IMPORTANT - If a transfer ribbon is installed incorrectly by the operator, damage to the print head may result. 5) DO NOT use a ribbon when printing with direct thermal media Rev. B v

6 Media Reload Tip Print Quality Tip If you should run out of labels or ribbon while printing, DO NOT turn the power switch OFF (0) while reloading or data loss may occur. The printer will automatically resume printing when a new label or ribbon roll is loaded. Print den sity (darkness) is af fected by the heat energy (density setting) applied and by the print speed. Chang ing both Print Speed and Den sity may be re quired to achieve the de sired re sults. vi Rev. B

7 CONTENTS INTRODUCTION 1 Models Conventions Unpacking the Printer Preparing a Static-Safe Work Area Environmental and Shock Protection CLEANING AND MAINTENANCE 5 General Cleaning Cleaning the Media Path Print Head Considerations Media Path Considerations Cleaning Card Considerations Platen Considerations Lubrication Before Loading Media TROUBLESHOOTING GUIDE 11 Print Head Wear REQUIRED TOOLS 15 PARTS FOR WIDE PRINTERS 17 Latch Replacement - LP Top Cover Replacement - LP Print Head Replacement - LP Packing Materials Replacement Feet Replacement Front Bezel Replacement Front/Cutter Bezel Replacement Platen Replacement Bottom Case (Base Housing) Replacement Motor Replacement Black Line and Bottom Gap Sensors Replacement Head-Up Sensor Replacement Main Print Circuit Board Assembly Replacement Dispenser Bezel Replacement Latch Replacement - TLP Cover Support Replacement - TLP Hinge Replacement - TLP Upper Case (Top Cover) Replacement - TLP Ribbon Carriage Replacement - TLP Feed Button/LED and Top Gap Sensor Replacement - TLP Ribbon Motion Sensor Replacement - TLP Rev. B vii

8 Real Time Clock Option Print Head Replacement - TLP PARTS FOR NARROW PRINTERS 47 Feet Replacement Front Bezel Replacement Front/Cutter Bezel Replacement Platen Replacement Bottom Case (Lower Cover) Replacement Motor Replacement Black Line and Bottom Gap Sensors Replacement Head-Up Sensor Replacement Main Printed Circuit Board Assembly (PCBA) Replacement Dispenser Bezel Replacement Latch Replacement Upper Case (Top Cover) Replacement Feed/Gap Sensor Cable Assembly Replacement Feed/LED PCBA Replacement Real Time Clock Option Print Head Replacement - LP Latch Replacement - TLP Cover Support Replacement - TLP Hinge Replacement - TLP Upper Case (Top Cover) Replacement - TLP Ribbon Carriage Replacement - TLP Feed Button/LED and Top Gap Sensor Replacement - TLP Ribbon Motion Sensor Replacement - TLP Print Head Replacement - TLP CABLE ROUTING 83 Cable Routing for TLP Wide Printers Cable Routing for LP Wide Printers Cable Routing for LP Narrow Printers Cable Routing for TLP Narrow Printers viii Rev. B

9 INTRODUCTION If you are a field engineer or technician, this manual helps you with routine maintenance, troubleshooting and procedures for replacing parts for repair. Follow the parts replacement procedures as closely as possible. If you are unsure of any procedure, please contact your service representative or call the products technical support group at Zebra Technologies Corporation, (805) Zebra Technologies stocks all replacement parts for the printer. Be sure your facility stocks sufficient parts for the printer so that scheduled maintenance can take place in a timely manner Rev. B 1

10 Models There are several models of the printer, each of which look similar but have different ribbon and media handling features. LP models print using direct thermal media only. The top case is flat. TLP models print using either direct thermal or thermal transfer media. The top case flares at the front to enclose the carriage and ribbon spool hubs. There are models that can handle up to four-inch (102 mm) wide media and those that can handle up to two-inch (51 mm) wide media. All printers also have optional media handling functions such as the dispensers to present a single label already peeled from the backing or cutters to present a single label snipped from the roll. The power supply and firmware also are characteristics of the printer model and allow the printer to be used in various countries Rev. B

11 Conventions This manual uses the following notations to call attention to important information. ICON / SYMBOL MEANING WARNING - critical safety information. CAUTION - problem avoidance messages. STATIC SENSITIVE - follow procedures that protect against the discharge of electrostatic energy that accumulates on the surface of the human body or other objects as this discharge can damage or destroy the print head and other electronic components. HEAT - The print head becomes hot while printing. Protect against personal injury. DO NOT touch the print head. Use only the cleaning pen to perform maintenance. NOTE - important instructions and reminders. HINT - helpful information. Unpacking the Printer Printers are carton shipped and wrapped inside a protective electrostatic discharge (ESD) bag. Keep all packing materials in case you need to reship the printer later or store the printer for any length of time. Preparing a Static-Safe Work Area Prepare a static-safe work area before opening the printer for repair. The area must include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for the technician. ESD protective devices are available from most electronic supply stores or by contacting 3M corporation at (800) Rev. B 3

12 Environmental and Shock Protection Extreme temperature and humidity fluctuations or mishandling can damage the printer and power supply. Allow 30 minutes or more before opening the printer's plastic bag. This time allows the printer to stabilize temperature especially after storage in a cool, dry location and then placement in a warmer, more humid location. Warm, humid air condenses on the cool components of the printer and this condensation may damage the components. Move the printer carefully. Mechanical damage can certainly result from falls or rough handling Rev. B

13 CLEANING AND MAINTENANCE The printers are manufactured and tested under a strict quality management program. Zebra Technologies uses only high quality components and materials in its printers. Although only minimal routine maintenance is required, following these simple maintenance guidelines will ensure longer life with quality printing performance. General Cleaning Keep the outside your printer clean by periodically wiping it with a soft cloth dampened with water. Do not use abrasive cleaners as they will damage the surfaces. Shock Hazard - See page iv. Always turn off the printer before cleaning Rev. B 5

14 Cleaning the Media Path When you clean the printer, use one or more of the following supplies that best suits your needs: DESCRIPTION SPARE NUMBER Cleaning pens (12) Cleaning swabs (25) Cleaning cards, 4-in wide (25) Save-a-Print Head film, 4-in wide (3) The cleaning process takes just a couple of minutes using the steps outlined below. Printer Part Print head Platen roller Peel bar Tear bar Exterior Interior Cutter Method Let the print head to cool for one minute, then use a new cleaning pen to swab the print elements (the thin gray line on the print head) from end to end. NOTE: You do not have to turn off the printer to do this. If print quality remains poor after cleaning, try the Save-a-Print Head cleaning film to remove buildup without damaging the print head. Call your authorized reseller for more information. Manually rotate the platen roller. Clean it thoroughly with 70% isopropyl alcohol and a cleaning swab, cleaning card, or lint-free cloth. Clean it thoroughly with 70% isopropyl alcohol and a cotton swab. Clean it thoroughly with 70% isopropyl alcohol and a cotton swab. Water-dampened cloth Brush or air blow Use tweezers to remove scraps Interval As necessary or after every five rolls of media As needed Rev. B

15 Adhesives and coatings of media can over time transfer onto the printer components along the media path including the platen and print head. This build-up can accumulate dust and debris. Failure to clean the print head, media path and platen roller could result in inadvertent loss of labels, label jams and possible damage to the printer. Print Head Considerations When handled during installation, and over time, the print head may become contaminated resulting in poor print quality. After installing a new print head or after using a roll of media or ribbon, rub the cleaning pen across the dark area of the print head. Allow the print head to dry for one minute before loading labels. Always use a new cleaning pen on the print head (an old pen carries contaminants from its previous uses that may damage the print head). Media Path Considerations Avoid touching the print head whenever possible. To remove dirt or dust, always gently clean the print head with a cleaning pen or a cotton swab moistened with 70% isopropyl alcohol. Use a cleaning swab or pen to remove debris, dust or crust that has built-up on the holders, guides and media path surfaces. 1. Use the alcohol in the cleaning swab or pen to soak the debris so that it breaks up. 2. Wipe the area with the cleaning swab or pen to remove the debris. 3. Discard the cleaning swab or pen after use Rev. B 7

16 Cleaning Card Considerations Use a cleaning card to remove debris that has built-up on the platen. Avoid scrubbing or vigorously rubbing the platen; otherwise, the surface could be damaged. 1. Open the printer and remove labels. 2. Place the cleaning card into the label path so that it is under the guides and it extends between the print head and platen roller. 3. Close and latch the printer. 4. With the power switch on, press the feed switch to move the cleaning card through the printer. 5. Discard the card after use. Platen Considerations The standard platen (drive roller) normally does not require cleaning. Paper and liner dust can accumulate without effecting print operations. Contaminates on the platen roller can damage the print head or cause the media to slip when printing. Adhesive, dirt, general dust, oils and other contaminates should be cleaned immediately off the platen. However, the non-stick platen roller on linerless media printers requires frequent cleaning to keep adhesive buildup from occurring and transferring to the print head and the media path. Keep a new platen available as a spare and install it whenever the printer has significantly poorer performance, print quality or media handling. If sticking or jamming continues even after cleaning, you must replace the platen. The platen can be cleaned with a fiber-free swab (such as a Texpad swab) or a lint free, clean, damp cloth very lightly moistened with medical grade alcohol (70% pure or better). 1. Open the media door and remove the media. 2. Clean the platen surface with the alcohol moistened swab. Rotate the platen while swabbing. Repeat this process two to three times with a new swab to remove residual contaminates. Adhesives and oils, for example, may be thinned by the initial cleaning but not completely removed. 3. Discard the cleaning swab or pen after use. Allow the printer to dry for one minute before loading labels. Lubrication No lubricating agents of any kind should be used on this printer! Some commercially available lubricants, if used, will damage the finish and the mechanical parts inside the printer Rev. B

17 Before Loading Media You must remove the outside length of media (that is, one, full revolution of labels and any liner). When you remove this part of the media, you remove the oils, dust, and adhesives that contaminate it. Tape or adhesive holds the loose end and the outside length of media becomes contaminated when handled or stored. You must avoid dragging adhesive or dirty media between the print head and platen. Such an occurrence damages the print head and is not covered under the warranty. Using clean media prevents damage and reduces wear on the print head and platen Rev. B 9

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19 TROUBLESHOOTING GUIDE PROBLEMS Status indicator does not light when power switch is on (I) Printer is in dump mode but nothing prints after sending file. ASCII characters print in place of expected label art and bar codes. Printing is uniformly faded or poor quality. SOLUTIONS 1. Check power connections from the printer to the outlet. 1. File does not contain a form feed code that will advance sheet. Press the Feed button to print data in the printer s buffer. 1. Printer may be in dump mode. Press the Feed button to reset to normal operation. 2. Check serial port configuration using the Y command. See the EPL2 programmer s manual. 1. Wipe the print head with the cleaning pen. 2. Adjust print speed/darkness in software or with programming. 3. Check the roll and verify that the media print surface is facing up. 4. Verify that the correct combination thermal transfer ribbon and media are in use Rev. B 11

20 PROBLEMS Printer appears to be working with the indicator light GREEN, but nothing is printed. Printing stops and status indicator lights red Status indicator remains red. Rubbing noise when pressing Feed button. Cutter makes incomplete cuts or cuts in the wrong spot. Short length, perforated media are difficult to load when preparing for dispenser/peel mode. SOLUTIONS 1. Check the connections between the printer and the cable as well as the cable and the computer. 2. Verify that the labels are the correct type. 3. Check the roll and verify that the print surface faces up for direct thermal printing. 4. Check that the transfer ribbon is correctly routed and has the ink side down. 5. Check print head wire bundle connections in carriage at main PCBA. 1. Perform the AutoSense adjustment. 2. Check that gap between labels is at least 1/16 inch (1.6mm) 3. Check for media jam. 4. Check that media is correctly routed. 5. Check printer memory configuration and correct data syntax. 6. Transmissive (gap) is dirty. Clean media path. 1. Check for out-of-media condition or missing labels in the middle of a roll. 2. Check for out-of-ribbon condition or damage or previous use of ribbon in middle of roll. 3. Check that the ribbon and label stock or correctly routed 4. If using direct thermal printing, check that programmed mode or printer driver is set for direct thermal printing. See the programmer s book for details. 5. Transmissive (gap) sensor may be dirty. Clean media path. 6. Check that the printer carriage is closed and latched. 1. Media is not loaded and the platen is rubbing against the print head. Insert media (and load ribbon if necessary) between carriage and platen. 1. Form length is set wrong. Change length through printer driver or programming language. See the EPL2 programming manual. 1. Media length must be a minimum of 0.5 inch (12.7mm) Rev. B

21 PROBLEMS Printer firmware must be updated. SOLUTIONS The printer firmware is updated by way of the parallel port. 1. Use the download utility to send firmware to the printer. 2. Optionally, you can download from the c:\ prompt by typing copy/b filename lpt1: from the directory holding the update file. The printer's light should start flashing green-orange, and then every few seconds will flash red a couple of seconds. Once the update is done, the light goes dark then comes on green Rev. B 13

22 Print Head Wear The print head has a limited life and is considered a consumable item. The media rubs across the print elements and wears away the surface. Media material, operational settings, and environment all affect this process. Printing with worn elements may create illegible images. If the print quality remains poor after cleaning, you may need to replace the print head. Damage can be caused by improper cleaning (unapproved fluids or implements), electrostatic discharge (ESD), or touching the print head (contaminating it with bodily, oily acids). Examples of poor print: Weak or Damaged Print Elements (Full-On Print Pattern) Weak or Damaged Print Elements or Print Logic (Rotating Print Element Pattern) The print head on the left is brand new. The print head in the center has been run over a million inches and has been cleaned after each media roll (and/or ribbon). The print head on the right has been run less than a million inches without cleaning and wear is evident Rev. B

23 REQUIRED TOOLS Make use of the following tools while performing replacement procedures: Phillips driver #0 Phillips driver #1 Phillips driver #2 Slot-head screwdriver tweezers needle-nose pliers cutters pliers for integrated chips Rev. B 15

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25 PARTS FOR WIDE PRINTERS This section includes procedures that are specific to the 4-inch-wide printers. Both the LP and TLP models can print on direct thermal media. The TLP model can also print using ribbons and thermal transfer media. Most models print at 200 dots per inch at up to four inches per second; the 3842 model prints at 300 dots per inch at up to two inches per second Rev. B 17

26 REPAIR PATHS 405 Base Housing (Bottom) 290 LP2844 Print Head 211 LP Latch (Top Cover) 402 Front Bezel 401 Rubber Feet 404 Platen 403 Cutter Option 409 Main PCBA 408 Head-Up Sensor 407 Black Line Sensor Assy 406 Platen Motor 410 Dispenser Label-Taken 418 Real-Time Clock Option 214 Top Cover LP 2443 Orion LP 2844 LP 2844-Z DA Base Housing (Bottom) 490 TLP2844 Print Head 411 TLP Latch (Top Cover) 402 Front Bezel 401 Rubber Feet 404 Platen 403 Cutter Option 409 Main PCBA 408 Head-Up Sensor 407 Black Line Sensor Assy 406 Platen Motor 410 Dispenser Label-Taken 418 Real-Time Clock Option 413 Hinge 414 Upper Case Assembly 415 Ribbon Carriage 417 Ribbon Motion Snsr 412 Upper Cover Support 416 Feed Button Top Gap Snsr TLP 2844 TLP 2844-Z TLP 3842 TLP 3844-Z R Rev. B

27 Latch Replacement - LP A Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Open the printer by pulling the release latches forward, then lifting the top cover. Remove media. Removal 1. Use a #1 Phillips driver to loosen the four screws that hold the latch frame! to the top case ". 2. Detach the springs on both sides from where they engage the latch frame #$. 3. Unsnap the latch shaft from its bearings in the frame. Assembly 1. Make sure the springs are engaged on the latch handles %&. 2. Align the latch assembly so that the hooks face the rear. Snap the latch shaft into its bearings on the frame. 3. Engage both springs into the top hole on the latch frame. 4. Align the latch frame up to the top case and ensure that the cables are not bent or pinched. 5. Replace the four screws that hold the latch frame to the top case and use a #1 Phillips driver to tighten them. 6. Clean the print head with the cleaning pen. Assembling the Printer Reload media. Plug in the power cord, turn on the printer and run the AutoSense routine to get a dump mode printout Rev. B 19

28 Top Cover Replacement - LP A Preparation Perform the removal steps of the Bottom Case ( ) and Main PCBA ( ) replacement procedures. Removal 1. Unwrap the ribbon cables and wire bundles from the ferrite core. 2. Use a #1 Phillips to loosen the hinge & between top cover and bottom assembly. 3. Use a #1 Phillips to loosen the screws that hold the latch frame % to the cover. 4. Use a #1 Phillips to loosen the screws that hold the feed/led PCBA $ to the cover. 5. Detach the ribbon cable # from the feed/led PCBA. 6. Pull the latch frame, feed/led PCBA and print head cables out of the cover. Assembly 1. Route the print head cables!" from the latch frame through the cover. Refer to the diagram in the Cable Routing section. 2. Attach the ribbon cable # to the feed/led PCBA. 3. Align the feed/led PCBA $ in the top cover and tighten the two screws to hold it. 4. Align the latch frame % in the cover and use a #1 Phillips to tighten the four screws to hold it Rev. B

29 Top Cover Replacement - LP 2844 (continued) A 5. Route the left print head wires through the hinge & and the right print head wires and PCBA ribbon cable through lower frame '. 6. Align the hinge in place and use a #1 Phillips to tighten the single screw that holds it. Assembling the Printer Perform the assembly steps of the Main PCBA ( ) and Bottom Case ( ) replacement procedures Rev. B 21

30 Print Head Replacement - LP A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Open the printer by pulling the release latches forward, then lifting the top cover. Remove media. Removal 1. Use a #1 Phillips driver to loosen the four screws that hold the latch frame ' to the top case (. 2. Grasp the print head spring and pull it to the left; then, slide it free of the latch frame. 3. Gently pull the wire bundles #$ from the print head. 4. Use a #1 Phillips driver to loosen the two screws and release the print head from the latch frame ' and bracket &. Assembly 1. Route the print head cables #$ under latch shaft and plug into the receptacles!" on the print head. 2. Hold the print head against the print head bracket & while replacing the screws and washers; attach the ground wire % using the right screw and washer. Use a #1 Phillips driver to tighten the screws. 3. Slip the left end of the print head spring into the left side of the latch bracket '; then slide the right end into the other side. The angle of the "v" fits into the indent on top of the print head bracket Rev. B

31 Print Head, LP 2844 Replacement A 4. Align the latch bracket up to the top case ( and ensure that the cables are not bent or pinched. 5. Replace the four screws that hold the latch bracket to the top case and use a #1 Phillips driver to tighten them. 6. Clean the print head with the cleaning pen. Assembling the Printer Reload media. Plug in the power cord, turn on the printer and run the AutoSense routine to get a dump mode printout Rev. B 23

32 Packing Materials Replacement A To ship or store the printer, make sure all components are packed as shown. Foam set Master carton all-in-one Poly-bag Ship kit (varies per printer) Extreme temperature and humidity fluctuations or mishandling can damage the printer and power supply. When unpacking the printer, allow 30 minutes or more before opening the plastic bag. This time allows the printer to stabilize temperature especially after storage in a cool, dry location and then placement in a warmer, more humid location. Warm, humid air condenses on the cool components of the printer and this condensation may damage the components. Move the printer carefully. While the printer has sturdy construction, mechanical damage can certainly result from falls or rough handling Rev. B

33 Feet Replacement A Preparations Tilt the printer to access the bottom. Removal Pry the foot off the base! using a levering tool if necessary. Assembly 1. Peel the foot off of its backing. 2. Place the sticky adhesive (top of foot) into its receptacle " on the bottom case Rev. x1

34 Front Bezel Replacement A Preparations Open the printer by pulling the release latches forward, then lifting the top cover. Removal Use a small slot-head screwdriver to pry either side free and then lift the bezel away from the printer. Assembly Align the tabs with the notches in the media exit and snap the bezel into place Rev. B

35 Front/Cutter Bezel Replacement A Preparations Open the printer by pulling the release latches forward, then lifting the top cover. Removal 1. Use a small slot-head screwdriver to pry either side free and then lift the bezel away from the printer. 2. Unplug the connector. Assembly 1. Align the cutter so that the connector is to the rear. 2. Plug the connectors together. 3. Align the tabs with the notches in the media exit and snap the bezel into place Rev. B 27

36 Platen Replacement A Preparations Open the printer by pulling the release latches forward, then lifting the top cover. Removal 1. Use the blade of a small slotted screw driver to pry the peg! free from its hole and rotate the bearing forward a quarter turn. Repeat on the other side ". 2. Pinch both tabs then lift the platen free of the printer. Assembly 1. Align the platen so that its gear # is to the left. 2. Pinch both tabs (pressing inward) and put each bearing into its slot. 3. Rotate each tab backward until the peg snaps into its hole. Older 2443 printers have only one tab (! ) securing the platen with a bearing on the right Rev. B

37 Bottom Case (Base Housing) Replacement A Removal 1. Tilt the printer so you can see the bottom. 2. Use a #1 Phillips driver to remove the three screws that secure the bottom case to the bottom frame. 3. Pull the bottom case off of the bottom frame. Assembly 1. Align the bottom case to the bottom frame. 2. Replace the three screws that hold the case to the frame; then, use a #1 Phillips driver to tighten them Rev. B 29

38 Motor Replacement A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the Bottom Case Replacement procedure ( ). Removal 1. Unplug the wire bundle! from the motor where it attaches to the main PCBA ". Note its location. 2. Use a #2 Phillips to remove the screws that hold the motor to the left side frame of the media frame. Assembly 1. Align the motor so that its gear is to the left; then, insert it through the left side frame of the media frame. 2. Replace the two screws that hold the motor to the side frame; then, use a #2 Phillips driver to tighten them. 3. Twist the wires at least three times; then, plug the wire bundle from the motor into its connector on the main PCBA. Assembling the Printer Perform the assembly steps of the Bottom Case Replacement procedure ( ). Check the installation. Turn on the printer and run the AutoSense routine to get a dump mode printout. This action tests the printer's media drive and printing capabilities Rev. B

39 Black Line and Bottom Gap Sensors Replacement A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the Bottom Case Replacement procedure ( ). Removal 1. Unplug the ribbon cable! from the sensor where it attaches to the main PCBA ". Note its location. 2. Use a #1 Phillips to remove the screw that holds the sensor to the bottom of the media frame. Assembly 1. Align the sensor in place it on the bottom of the media frame. 2. Use a #1 Phillips driver to replace and tighten the screw that holds the sensor to the frame. 3. Plug the ribbon cable from the sensor into its connector on the main PCBA. Assembling the Printer Perform the assembly steps of the Bottom Case Replacement procedure ( ). Check the installation. Turn on the printer and run the AutoSense routine to get a dump mode printout. This action tests the printer's media drive and printing capabilities Rev. B 31

40 Head-Up Sensor Replacement A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the Bottom Case Replacement procedure ( ). Removal 1. Unplug the ribbon cable! from the sensor where it attaches to the main PCBA ". Note its location. 2. Use a #1 Phillips to remove the screw that holds the sensor to the bottom of the media frame. Cut away any tie-wrap. Assembly 1. Align the sensor so that its ribbon cable is to the left; then, place it one the bottom of the media frame. 2. Replace the screw that holds the sensor to the frame; then, use a #1 Phillips driver to tighten it. 3. Plug the ribbon cable from the sensor into its connector on the main PCBA. New head-up sensors include a ferrite-core and a tie-wrap and anchor to secure the ribbon cable to the frame. Assembling the Printer Perform the assembly steps of the Bottom Case Replacement procedure ( ). Check the installation. Turn on the printer and run the AutoSense routine to get a dump mode printout. This action tests the printer's media drive and printing capabilities. Connector Anchor Ferrite Core Tie-Wrap Head-Up Sensor Main PCBA Media Guide Motor Adjustment Knob Rev. B

41 Main Print Circuit Board Assembly Replacement A Preparation Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Check your work when connecting the print head cables For 2844 models, the right bundle of wires plugs into the right connector (J17) and the left bundle plugs into the left connector (J19) on the main PCBA. For 2443 models, the right bundle plugs into J3 and the left bundle plugs into J2 on the main PCBA. If connected wrong, permanent damage can result to the printer. Perform the removal steps of the Bottom Case Replacement procedure ( ). Removal 1. Use a #1 Phillips driver to remove the screw that secures the board to the lower frame!. 2. Unplug the wire bundles, ribbon cables and ground wire from their connectors on the board. Make note of their locations and routes. Assembly 1. Plug the wire bundles, ribbon cables and ground wire into their connectors on the board. 2. Align the protective separator " against the bottom frame. 3. Align the board onto the standoffs #. 4. Replace the screw that hold the board to the front standoff and use a #1 Phillips driver to tighten it. Assembling the Printer Perform the assembly steps of the Bottom Case Replacement procedure ( ). Check the installation. Turn on the printer and run the AutoSense routine to get a dump mode printout. This action tests the printer's media drive and printing capabilities Rev. B 33

42 Dispenser Bezel Replacement A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the Bottom Case Replacement procedure ( ). Removal 1. Pry either side free and then lift the bezel away from the dispenser bar and bottom frame assembly. 2. Note the location of the connector! on the main control board; then unplug it. 3. Pull the wires and connector through the frame access ". Replacing the Dispenser Switch PCB Find the dispenser PCB. Slip the ribbon cable out of the dispenser access # then snap the PCB out of/into the dispenser bezel. Assembly 1. Align the bezel so that the connector is to the rear. 2. Thread the connector and wires through the access. 3. Plug the connector into its location on the main control board. 4. Align the tabs with the notches in the media exit and snap the bezel into place. Assembling the Printer Perform the assembly steps of the Bottom Case Replacement procedure ( ). Check the installation. Turn on the printer and run the AutoSense routine to get a dump mode printout. This action tests the printer's media drive and printing capabilities Rev. B 34

43 Latch Replacement - TLP A Preparations Open the printer by pulling the release latches forward, then lifting the top cover. Removal Unsnap the latch assembly from both bearings!" in the top case. Assembly 1. Squeeze the latch handles #$ inward and press into the top case. 2. Push the cross bar % into each bearing until it snaps into place Rev. B 35

44 Cover Support Replacement - TLP A Preparations Open the printer by pulling the release latches forward, then lifting the top cover. Removal 1. Use a #1 Phillips driver to remove the two screws holding the support to the top assembly!. 2. Lift the support away from the bottom assembly ". Assembly 1. Align the support so that the square brace fits into the top assembly. 2. Insert the support into the bottom assembly. 3. Replace the two screws that hold the support the top assembly and use a #1 Phillips driver to tighten them Rev. B

45 Hinge Replacement - TLP A Preparation Perform the removal steps of the Bottom Case ( ) and Main PCBA ( ) and Cover Support ( ) procedures. Removal 1. Use a #1 Phillips driver to loosen and remove the screw that holds the hinge lock onto the bottom media frame!. 2. Slide the hinge off of the frame. 3. Slide the top cover assembly " and bottom media frame apart. Installation 1. Ensure the wires follow their correct routing. On the side opposite the hinge, make sure the cables go through the channel '. 2. Slide the top cover assembly and bottom media frame together. 4. Align the hinge with the link tab # facing right and insert into the top cover assembly. Note: Make certain that the link tab engages with the link $ inside the top case. 5. Fit the hinge onto the bottom media frame. 6. Replace the screw and use a #1 Phillips driver to tighten it. 7. Ensure the hinge caps %& are inserted properly. Assembling the Printer Perform the assembly steps of the Cover Support ( ), Main PCBA ( ) and Bottom Case ( ) procedures Rev. B 37

46 Upper Case (Top Cover) Replacement - TLP A Preparation Perform the removal steps of these procedures: Bottom Case Replacement ( ), Main PCBA Replacement ( ), and Hinge Replacement ( ). Removal 1. Loosen the four screws and that hold the upper frame to the top case. 2. Lift the frame away from the window and top case. Notice that the feed/led cable % leads to the button assembly attached to the top case. Assembly 1. Align the window so that the holes at the rear engage on the pegs of the upper frame. Refer to the diagram in the Cable Routing section. 2. Check that the link is in place across the ribbon carriage and upper frame. 3. Lower the top case onto the window and frame. 4. While holding the frame, window and top case together, flip them over so that they rest on the window. 5. Replace the four screws that hold the frame to the top case and use a #1 Phillips driver to tighten them. Assembling the Printer Perform the assembly steps of these procedures: Hinge Replacement ( ), Main PCBA Replacement ( ), and Bottom Case Replacement ( ) Rev. B

47 Ribbon Carriage Replacement - TLP A Preparation Perform the removal steps of these procedures: Bottom Case Replacement ( ), Main PCBA Replacement ( ), Hinge Replacement ( ), and Upper Case Replacement ( ). Removal 1. Gently flex the left bearing! to release the left hinge of the carriage. 2. Gently flex the right bearing " to release the right hinge of the carriage. 3. To free the carriage from the upper frame, cut the rear tie wrap to free the wire bundles and ribbon cables; then, pull them free of the case and rear hinge of the upper frame. Assembly 1. Route the ribbon cables and wire bundles along the right side of the upper frame; then, secure them all with a tie wrap above the cover support location. Refer to the diagram in the Cable Routing section. 2. Snap both hinges into the bearings. Assembling the Printer Perform the assembly steps of these procedures: Upper Case Replacement ( ), Hinge Replacement ( ), Main PCBA Replacement ( ), and Bottom Case Replacement ( ) Rev. B 39

48 Feed Button/LED and Top Gap Sensor Replacement - TLP A Preparation The feed button LED PCB and the top gap (receive) sensor are one assembly. To access them, perform the removal steps of these procedures: Bottom Case Replacement ( ), Main PCBA Replacement ( ), Hinge Replacement ( ), Upper Case Replacement ( ), and Ribbon Carriage Replacement ( ). Removal 1. In the top cover!, use a #1 Phillips driver to remove the two screws "# that hold the PCB, and button. 2. On the upper frame $, use a #0 Phillips driver to remove the screw % that holds the metal brace & and upper gap sensor in place. 3. Lift the opaque button and clear lens away from the top cover. Assembly 1. With the top cover upside-down, insert the both button into place. 2. Align the feed button/led PCBA so that the ribbon cable faces the closest sidewall. 3. Replace the two screws that hold the LED PCBA and use a #1 Phillips driver to tighten them. 4. Align the top gap sensor so that the ribbon cable goes to the right of the upper frame. 5. Align the metal brace that holds the upper gap sensor. 6. Replace the screw that holds the brace and sensor and use a #0 Phillips driver to tighten it. 7. Route the sensor's wires through their guides. Refer to the diagram in the Cable Routing section Rev. B

49 Feed Button/LED and Top Gap Sensor Replacement (Continued) A Assembling the Printer Perform the assembly steps of these procedures: Ribbon Carriage Replacement ( ), Upper Case Replacement ( ), Hinge Replacement ( ), Main PCBA Replacement ( ), and Bottom Case Replacement ( ) Rev. B 41

50 Ribbon Motion Sensor Replacement - TLP A Preparation Perform the removal steps of these procedures: Bottom Case Replacement ( ), Main PCBA Replacement ( ), Hinge Replacement ( ), Upper Case Replacement ( ), and Ribbon Carriage Replacement ( ). Removal 1. On the ribbon carriage, cut the tie wrap! that holds the wire bundles and ribbon cables to the right side frame. 2. Use a #1 Phillips driver to loosen the screw " that holds the sensor to the outside of the left side frame. 3. Pull the sensor away from the carriage and pull the wires through both side frames. Assembly 1. Insert the connector through the outside of the left side frame. 2. Insert the connector through the inside of the right side frame. 3. Pull the wires through, and route them through their guides. 4. Align the sensor so that the wires go to the rear of the carriage. 5. Replace the screw that holds the sensor to the left side frame and use a #1 Phillips driver to tighten it. 6. Secure the wire bundles and ribbon cables against the carriage with a tie wrap inserted through the right side frame. Assembling the Printer Perform the assembly steps of these procedures: Ribbon Carriage Replacement ( ), Upper Case Replacement ( ), Hinge Replacement ( ), Main PCBA Replacement ( ), and Bottom Case Replacement ( ) Rev. B

51 Real Time Clock Option A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Perform the removal steps of the Bottom Case ( ) and Main PCBA ( ) replacement procedures. Installation The socket for the real-time clock option is designated as U15 on 2443 printers, U24 on both TLP and LP2844 printers. 1. Align the real time clock chip above its location on the main PCBA. Make sure the notched end of the chip is oriented correctly to the outline on the board. 2. Lower the real time clock chip into place taking care not to bend any of the pins. Assembling the Printer Perform the assembly steps of the Main PCBA ( ) and Bottom Case ( ) replacement procedures. Checking the Installation Turn on the printer and run your printer's AutoSense rou tine to get a dump mode print out. This ac tion tests the printer's media drive and printing capabilities. You can also check the print out. 8 UKQ1775 V3.20 Serial port : 96,N,8,1! Firmware version number " Memory (available bytes) # Real time clock option (when installed) Image buffer size:0507k Fmem:000.5K,060.9K avl Gmem:024K,0045K avl Emem:000K,0045K avl I8,0,001 rn S4 D10 R064,000 ZT UN q1600 Q1209,026 Option: Date: Time: 12:44:00 now in DUMP Rev. B 43

52 Print Head Replacement - TLP A Preparations Protect against static discharge. Your work area must be static-safe and include a properly grounded conductive cushioned mat to hold the printer and a conductive wrist strap for yourself. Open the printer by pulling the release latches forward, then lifting the top cover. Remove any ribbon from the carriage. Removal 1. Grasp the print head spring and pull it to the left; then, slide it free of the carriage. 2. Use the spring to pry the print head clip off the right side of the carriage. 3. Pull the print head and bracket forward. 4. Use a #2 Phillips driver to remove the screw that holds the ground wire. 5. Unplug both bundles #$ of print head wires from the left and right connectors. Assembly 1. Align the print head and bracket to plug the left! and right " connectors into the black # and white $ wire bundles. 2. Attach the ground wire % and secure it with the screw. Use a #2 Phillips driver to tighten it. 3. Insert the bracket pegs & into the left side of the carriage. 4. Align the right side of the bracket and insert the print head clip through the right side of the ribbon carriage into the bracket Rev. B

53 Print Head Replacement - TLP (continued) A 5. Slip the left end of the print head spring into the left side of the ribbon carriage; then slide the right end into the other side. The angle of the "v" fits into the indent on top of the print head bracket '. 6. Clean the print head with the cleaning pen. Assembling the Printer Reload media and ribbon. Plug in the power cord, turn on the printer and run the AutoSense routine to get a dump mode printout Rev. B 45

54 Rev. B

55 PARTS FOR NARROW PRINTERS This section includes procedures that are specific to the 2-inch-wide printers. Both the LP and TLP models can print on direct thermal media. The TLP model can also print using ribbons and thermal transfer media. These models print at 200 dots per inch at up to four inches per second Rev. B 47

56 REPAIR PATHS 305 Base Housing (Bottom) 304 Platen 302 Front Bezel 301 Rubber Feet 303 Cutter Option 390 LP 2824 Print Head 309 Main PCBA 308 Head-Up Sensor 307 Black Line Sensor Assy 306 Platen Motor 310 Dispenser Label-Taken 316 Fd-Gap Snsr Cable Assy 314 Cover (Top) Housing 318 Real-Time Clock Option 317 Feed/LED PCBA 311 Latch (Top Cover) LP Base Housing (Bottom) 590 TLP 2824 Print Head 511 TLP Latch (Top Cover) 302 Front Bezel 301 Rubber Feet 304 Platen 303 Cutter Option 309 Main PCBA 308 Head-Up Sensor 307 Black Line Sensor Assy 306 Platen Motor 310 Dispenser Label-Taken 318 Real-Time Clock Option 513 Hinge 514 Upper Case Assembly 515 Ribbon Carriage 517 Ribbon Motion Snsr 512 Upper Cover Support 516 Feed Button Top Gap Snsr TLP Rev. B